DigiFab

=Welcome to the Digital Fabrication Page for AE 597F=

What is Rapid Prototyping?

 * Rapid Prototyping is the process of producing a physical model of design within a short amount of time (within one week)
 * The model is used to determine form, fit, and function of a design prior to production
 * Additional information can be found through the following [|link]

Rapid Prototyping Technologies on Campus
(click on the links below for a process overview) The Basic RP Process Workflow
 * [|Fused Deposition Modeling (FDM)]in the Learning Factory
 * [|3-D Printing] in the Stuckman Family Building (SALA)
 * [|Stereolithography Apparatus (SLA)] in the Leonhard Building

FDM (Fused Deposition Modeling) Utilizing the BST 1200 Printer in the Learning Factory.

 * 1) Create 3-D Model (Revit, 3D CAD, FormZ)
 * 2) Export 3-D Model to .dwg format [FormZ software can directly export an .stl file]
 * 3) Import the .dwg into 3-D Studio Max (or Viz)
 * 4) Scale the model (if necessary)
 * 5) Export form Studio Max to a .stl file format
 * 6) Slice the .stl file into layers using Catalyst EX software
 * 7) Construct the model using the Dimension BST 1200
 * 8) Remove support structures in the ultrasonic bath
 * 9) Clean and finish the model

3-D Printing Utilizing the ZCorp Printer in the SALA (Stuckman Family) Building.
 * 1) Create 3-D Model (Revit, 3D CAD, FormZ)
 * 2) Export 3-D Model to .dwg format [FormZ software can directly export an .stl file]
 * 3) Import the .dwg into 3-D Studio Max (or Viz)
 * 4) Scale the model (if necessary)
 * 5) Export form Studio Max to a .stl file format
 * 6) Slice the .stl file into layers using ZPrint 310 software
 * 7) Construct the model using the ZPrinter 310 Plus
 * 8) Remove extra dust on the model in the spray booth with the compressed air gun
 * 9) Finish the model by coating it lightly with Z-Bond 101 or clear spray paint

Troubleshooting/Tips:

 * Note: For best results read the Troubleshooting/Tips page prior to printing your 3D model.**
 * Problem**: The .STL file will not open, or when it does it is incorrect, such as a bunch of random points everywhere.
 * Solution**: Verify that the .STL file was created from Revit, 3D CAD or FormZ.


 * Problem**: When I printed the model it broke easily.
 * Solution**: The electronic model should be created to the dimensions you actually want the final product. Try to avoid scaling, though if scaling is required, scale the model before converting to a .STL format. Try to draw all parts of the models to at least 1/16” thick – and thicker if it supports the structure.

__For the FDM Process__: Ensure that the ultrasonic bath is clean. __For the ZCorp Printer__: Use Z-Bond 101 to finish the model for best results and use a light coat for best results. If you choose to use clear spray paint, use a light coat to prevent discoloration.
 * Problem**: The model turned yellow after I finished it.
 * Solution**:


 * Problem**: My support structure did not completely dissolve in the ultrasonic bath.
 * Solution**: Use an exacto-knife to cut away the remaining supports. It is also recommended breaking away the non-intricate supports prior to the ultrasonic bath.

A:** The FDM process cost $8.00/in3. The ZCorp Printer cost approximately $4.00/in3 (it is a function of the binder quantity).
 * Q: How much does it cost to construct a model?

A:** The FDM process takes approximately 45 minutes/in3 of model, and then another 45 minutes/in3 in the ultrasonic bath. The ZCorp Printer takes approximately 4 hrs to construct an 8” x 8” model.
 * Q: How long does it take to construct the model?

A:** The 3D printing technologies allow for smaller model construction capabilities directly from CAD models, saving time and providing better results. The smaller construction tolerances of 0.004 inch is beneficial for constructing smaller building models that are to be a part of a site plan, also to provide greater detail on a larger sized model, allowing for the window sills, mullions, roof details, stairs, etc... to be constructed.
 * Q: What is the benefit of using this technology over, let's say, chipboard model construction?

Contact Information:
Jamie Heilman Architecture Department 0128 Stuckeman Family Building jrh225@psu.edu
 * For additional information on the ZCorp Printing process, including printing availability and costs, please contact the following:**

Carson M Baird Engineering Department Superviser of Engineering Labs 0101 Engineering Services cxb290@psu.edu
 * For additional information on the FDM Printing process, including printing availability and costs, please contact the following:**

Dragana Nikolic Architectural Engineering Department Grad Student Engineering Unit B dun113@psu.edu
 * For additional information on the Wikispaces used to create this website, please contact the following:**

IV. Reference Sources

 * [|ZCorp Printing]
 * [|Dimension Printing]